Adani Power Limited Power Business Goal - 20,000 MW
ADANI POWER AT A GLANCE • Power Business Goal - 20,000 MW BY 2020 • MUNDRA – 330MW X 4 + 660MW X 5 • TIRODA – 660MW X 5 (UNDER COMMISSIONING) • KAWAI – 660MW X 2 (UNDER ERECTION) • BITTA – 40MW BIGGEST SOLAR IN INDIA
ACHIEVEMENTS • INDIA’S FIRST 66O MW SUPER CRITICAL UNIT SYNCHRONISED BY ADANI POWER LTD, MUNDRA IN OCT 2010 IN RECORD TIME OF 36 MONTHS. • COMMISSIONED 4Nos. 660MW UNITS IN A YEAR. • ADANI IS THE FIRST COMPANY IN INDIA TO EARN CARBON CREDIT.
WELCOME TO PRESENTED BY B.K.PANDEY APML, TIRODA
START-UP SEQUENCE • BOP SYSTEM READYNESS • BOILER FLUSHING: COLD/HOT • BOILER LINE UP AND LIGHT UP. • TURBINE LINE UP. • TURBINE ROLLING. • SYNCHRONISATION • PHASE CHANGE OVER • FULL LOAD
START UP MODES • COLD START UP:HP & IP SHAFT METAL TEMP <204 ° C • WARM START UP: HP & IP METAL TEMP IN BETWEEN 204 TO 400 ° C • HOT START UP :HP & IP METAL TEMP >400 ° C
Boiler Economiser 2x7 11+1 8 2x7 FCS LPT A HPT IPT LPT B 5 5 6 6 7 7 7 7 3 8 8 8 8 1 LPH -7A LPH -7B RH HPH - 1 LPH -8A LPH -8B Condensor (HP) Condensor Deaerator HPH - 2 (LP) EXT From CRH (MD BFBP 1x35%) TDBFP 2X50% HPH -3 CEP 3x50% 1994 TPH GSC CPP 1482 TPH LPH -6 LPH -5
PRE STARTUP READYNESS • HT/LT POWER SUPPLY READINESS • WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW & ACW. • CCCW SYSTEM • COMPRESSOR SYSTEM • AUXILIARY STEAM. (S/B UNIT OR AUX BOILER). • START CEP AND MDBFP. • CHECK THE BCP SYSTEM IS READY.
WHY BCP ? • TO ASSIST CIRCULATION IN BOILER WATER WALL • TO INCREASE THE CIRCULATION VELOCITY • TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD. • TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON WATER WALL TUBES. • TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS REDUCED.
BCP FILLING ,PURGING & FLUSHING • PURPOSE- - TO FILL THE MOTOR CAVITY. • RECOMMENDED MOTOR FILLING WATER QUALITY - CONDUCTIVITY <1 µs/cm - BOILER FEED WATER - TEMP.< = 45 O C CL - < = 50 PPM - - pH > = 6.5 - SUSPENDED SOLIDS < = 5 PPM • FILLING,PURGING & FLUSHING WATER REQUIREMENT - MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN
PRE BOILER FLUSHING • START CEP. • FILL & DRAIN FROM DEAERATOR UNTIL REQUIRED WATER QUALITY IS ACHIEVED. ( Fe<500 Ppb.) • START MDBFP. • START THE BOILER COLD/HOT FLUSHING TO REDUCE THE Fe & SiO2 CONTENT IN FEED WATER.
Boiler flushing SP SP START-UP LINE Sampling Fe + Below Above MIXER 500ppb 500ppb BCP WW ECO CW HOTWELL LINE
BOILER COLD FLUSHING COLD FLUSHING • WATER WALL TEMP REQUIRED 105-120 DEG.C (TEMP MAINTAINED BY DEAERATOR PEGGING STEAM) • COLD OPEN FLUSHING QUALIFIES Fe < 500PPB SiO2 < 100PPB • THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER LOSS AND IMPROVE QUALITY. • COLD CYCLIC FLUSHING QUALIFIES Fe < 100PPB SIO2 < 50PPB (ALL ANALYSIS FROM SEPARATOR DRAIN)
BOILER HOT FLUSHING HOT FLUSHING • WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE OIL GUNS OF BC ELEVATION) • HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB SIO2 > 50PPB • IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB SIO2 < 50PPB • HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB SIO2 < 30PPB • AFTER COLD FLUSHING START BCP WITH MINIMUM 30% FEED FLOW & THROTTLE FRS VALVE.
BOILER LINE UP AND LIGHT UP • FUEL OIL SYSTEM: LDO/HFO PUMPS • ESP HEATERS & RAPPERS • AIR FLUE GAS SYSTEM: APH,IDF, FDF & SCANNER FAN. • MAINTAIN AIR FLOW : 30% - 40%. • FURNACE PURGE: 300 Sec. • LIGHT UP BOILER WITH OIL GUNS AT BC (LDO) ELEVETION. • CONTINUE HOT FLUSHING UNTIL REQD.WATER QUALITY IS ACHIEVED • THEN TAKE CD ELEVETION GUNS. IF REQUIRED TAKE 2 NO. GUNS IN AB ELEVETION.
BOILER LINE UP AND LIGHT UP • CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE TIME OF OIL FIRING. • PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA • PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA • PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA • FURNACE EXIT GAS TEMP MUST BE BELOW 538 ° C FOR REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED). • CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE OF SH 50 ° C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).
LDO/HFO GUN Fuel Light Oil Fuel Pressure 0.8MPa-2.0MPa Fuel Flow 500kg/h -3000kg/h Atomizing Air Pressure 0.6MPa-1.2MPa Atomizing Air Flow 100-600kg/h Ignition Method HESI (20 joules/spark) Fuel Heavy Oil Fuel Pressure 0.8MPa- 2.0MPa Fuel Flow 1000-4000 kg/h Atomizing Steam Pressure 0.8MPa-1.2MPa Atomizing Steam Flow 100-400kg/h Ignition Method HESI (20 joules/spark)
TURBINE LINE UP • ENSURE: • LUBE OIL SYSTEM: IN SERVICE (0.8 MPA) • JACKING OIL SYSTEM:IN SERVICE ( 14 MPA) • TURBINE BARRING GEAR: 3-4 RPM • SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED • STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL IN AUTO) • H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA. • EH OIL SYSTEM: IN SERVICE (14 MPA)
TURBINE LINE UP • ENSURE TDBFP IN BARRING. • GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56 ° C - 111 ° C MORE THAN ROTOR TEMP & DEGREE OF SH > 50 ° C. • CHARGE THE GLAND SEAL SYSTEM OF TDBFP. • START THE VACUUM PULLING WITH VACUUM PUMP. MAINTAIN VACUUM -0.9 KG/CM2. • CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS STEAM PRESSURE AND FIRING RATE FOR ACHIEVING TURBINE ROLLING PARAMETERS.
COLD START UP CURVE
HOT ROLLING MS TEMP RH TEMP SPEED MS FLOW LOAD MS PRESS
PRE HEATING OF HP CASING. • PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150 ° C. • CRH PR 0.5-0.7 MPA/220-380 ° C. • OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY. • OPEN BDV VALVE FULLY. • OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS. • HEATING RATE SHOULD NOT BE MORE THAN 50 ° C PER HR. • HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP DIFFRENCE SHOULD BE WITHIN 50 ° C. • AFTER ATTAINING THE CASING TEMP > 150 ° C CLOSE THE RFV VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO CONDENSOR.
TURBINE WARM UP OPERATION MS HPBP IPT HPT Ventilator valve TO CONDENSER CRH NRV BDV RFV TO CONDENSER CRH LINE TURBINE STARUP PROCEDURE
TURBINE ROLLING • AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE INCREASED. • REQUIRED STEAM PARAMETERS BEFORE ROLLING – MS PR: 8.73 MPA, TEMP: 330-380 ° C – RH PR: 1.1 MPA , TEMP: 330 ° C - THE DEGREE OF SUPER HEAT > 56 ° C. • AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN VACUUM. • MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION. • GIVE THE SPEED SET POINT TO 600 RPM • CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER. • THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.
TURBINE ROLLING • SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100 RPM/MIN. • ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP CASING. • WHEN HP CASING TEMP >320 ° C.CLOSE THE HP CV’S. • SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP CURVE. • CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM • SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100 RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE. • AS PER PROCEDURE SYNCHRONISE THE UNIT.
LOADING • AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT FOR 30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF EXPANSION, CASING EXPANSION. • CHARGE EXTRACTION STEAM TO DEAERATOR. • TAKE MORE OIL GUNS IN EF/AB ELEVETION. • TAKE PA FANS & SEAL AIR FAN. • AFTER ACHIEVING FURNACE TEMP. MORE THEN 450 ° C. TAKE COAL MILL-B AT. STEAM T/PR 380 ° C/8.7 MPA. • INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD • AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING, CLOSE THE BDV AND VENTILATING VALVE. • INCREASE THE LOAD AT 3MW/MIN • CLOSE THE HP-LP BYPASS GRADULLY.
(MW) LOAD 165 330 495 660 350 SYNCHRONISE &CHARGE D/A 33MW 400 60MW MILL-B CUT IN IP TO HP CHANGE OVER (70MW) MILL-C CUT IN AT 100MW HPH CHARGED(150 MW) 450 2 ND TDBFP CUT IN(180MW) WET TO DRY CHANGE OVER 198MW MINUTES MILL-A CUT IN(210MW) OIL GUN CUT OUT (260MW) 500 MILL-D CIT IN (300MW) 330MW MILL-E CUT IN (430MW) 550 MILL-F CUT IN (540MW) 600 660 MW 650
LPT A LPT B FROM IPT EXHAUST 2 nd 2 nd 4 th 4 th 5 th 5 th 5 th 5 th 6 th 6 th 6 th 6 th LP HEATER 7A LP HEATER 7B LP HEATER 8B LP HEATER 8A CONDENSER CONDENSER HP HEATER HP HEATER LP HEATER 5 5 LP HEATER 6 6
TDBFP START UP • TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT 180 MW. • WARM UP THE TURBINE. • SLOWLY OPEN THE AUX STEAM MOV TO TURBINE. • PARAMETERS FOR ROLLING TDBFP. STEAM PRESSURE: 0.6 ～ 1.3MPA, STEAM TEMP: 50 DEG C MORE THAN CASING TEMP. • ROLL THE TDBFP AS PER PROCEDURE. • GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40 MIN.CHECK THE TSI PARAMETER • WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.
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